Dynamically responsive high efficiency cchp system

ABSTRACT

A highly efficient combined cooling, heating, and power (CCHP) system is capable of providing 100% utilization of an energy generator used by the system by distributing thermal and electrical outputs of the energy generator to loads and/or other storage apparatuses. The CCHP system includes an energy generator, which can be a fuel cell and a waste heat recovery unit that assists in recovering thermal energy from the energy generator and returning it to the energy generator, and/or providing it to a thermal load, or a storage as needed or desired.

RELATED APPLICATION DATA

This application is a continuation of U.S. patent application Ser. No.14/142,873, filed Dec. 29, 2013 and titled “Dynamically Responsive HighEfficiency CCHP System”, which claims the benefit of priority of U.S.Provisional Patent Application No. 61/788,532 filed Mar. 15, 2013, andtitled “Dynamically Responsive High Efficiency CCHP System”, U.S.Provisional Patent Application No. 61/788,300 filed Mar. 15, 2013, andtitled “System and Method of Regenerating Desulfurization Beds in a FuelCell System”, U.S. Provisional Patent Application No. 61/781,965 andfiled Mar. 14, 2013, and titled “Power Conversion System with a DC to DCBoost Converter”, and U.S. Provisional Patent Application No. 61/784,894filed Mar. 14, 2013, and titled “Hybrid Autothermal Steam Reformer forFuel Cell Systems”, each of which is incorporated by reference herein inits entirety.

FIELD OF THE INVENTION

The present invention generally relates to the field of combinedcooling, heating, and power systems. In particular, the presentinvention is directed to a dynamically responsive, high efficiency,combined cooling, heating, and power system.

BACKGROUND

Combined cooling, heating, and power (CCHP) systems can take on severalforms and have been known to include fuel cells. A fuel cell is anelectrochemical device which reacts hydrogen with oxygen to produceelectricity and water. The basic process is highly efficient, and fuelcells fueled directly by hydrogen are substantially pollution-free.Moreover, as fuel cells can be assembled into stacks of various sizes,fuel cell systems have been developed to produce a wide range ofelectrical power output levels and thus can be employed in numerousapplications.

Although the fundamental electrochemical processes involved in fuelcells are well understood, engineering solutions have proven elusive formaking efficient use of fuel cells, especially in residential and lightcommercial applications, where the power output demands of a fuel cellare not as significant as those in industrial and utility applications.The prior art approach of sophisticated balance-of-plant systems isunsuitable for optimizing and maintaining relatively low power capacityapplications and often result in wasted energy and systems that are notcost-effective.

Improvements in fuel cell efficiency can be realized if there isrecovery of the thermal energy produced by the fuel cell.

SUMMARY OF DISCLOSURE

In a first aspect, a combined cooling, healing, and power (CCHP) systemis disclosed that comprises an energy generator that simultaneouslyproduces electrical and thermal energy for a plurality of loadsincluding at least a structure; a waste heat recovery system thermallycoupled to the energy generator and including: a distribution system fordelivering thermal energy to the structure; and a cooling system forproviding conditioned air to the structure; wherein the waste heatrecovery system is configured to recover thermal energy from the energygenerator and to return a first portion of the recovered thermal energyto the energy generator and a second portion of the recovered energy tothe distribution system or the cooling system depending on the presentor future needs of the structure.

In another aspect, a combined cooling, heating, and power (CCHP) systemfor use in a residential or light commercial structure having electricand thermal loads is disclosed. The CCHP system comprises a fuel cellsystem having thermal and electrical outputs: a waste heat recoverysystem including: a thermal management module; a storage system; adistribution system; and a cooling system; and a control system incommunication with the fuel system and the waste heat recovery system,the control system configured to: receive a signal representative of arequired electrical or thermal load; determine whether any additionalloads are required by the structure after receiving the signal; andcommunicate with the fuel cell system and the waste heat recovery systemso as maximize the utilization of the electrical and thermal outputs ofthe fuel cell system.

In yet another aspect, a method of efficiently using an energy generatorcapable of simultaneously producing electrical and thermal energyoutputs is disclosed. The method comprises determining an electrical orthermal load need; determining which output of the energy generatorsatisfies the electrical or thermal load need; producing one of thesimultaneously produced energy outputs to meet at least a portion of theelectrical or thermal load need; directing the other of thesimultaneously produced energy outputs to another load or to an energystorage system.

BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of illustrating the invention, the drawings show aspectsof one or more embodiments of the invention. However, it should beunderstood that the present invention is not limited to the precisearrangements and instrumentalities shown in the drawings, wherein:

FIG. 1 is a block diagram of a combined cooling, heating, and powersystem according to an embodiment of the present invention;

FIG. 2 is a block diagram of a fuel cell system according to anembodiment of the present invention;

FIG. 3 is a schematic of a high temperature polymer electrolyte membranefuel cell according to an embodiment of the present invention;

FIG. 4 is a block diagram of a waste heat recovery system according toan embodiment of the present invention;

FIG. 5 is a block diagram of a combined cooling, heating, and powersystem according to another embodiment of the present invention;

FIG. 6 is a block diagram of a method of creating, delivering, andstoring co-produced energy according to an embodiment of the presentinvention; and

FIG. 7 is a block diagram of a computing environment that may be used toimplement a combined cooling, heating, and power system according to anembodiment of the present invention.

DESCRIPTION OF THE DISCLOSURE

A combined cooling, heating, and power (CCHP) system according to thepresent disclosure dynamically generates high efficiency power, heating,and/or cooling on demand. The CCHP system of the present disclosure canbe operated so as to produce high utilization of a fuel cell or group offuel cells (often referred to as a “fuel cell stack”), using both theelectric and thermal energy generated by the fuel cell for use within astructure throughout the year. In this way, the CCHP system providesnear complete energy recovery. Operationally, a CCHP system according toone or more embodiments of the present disclosure allows for the use ofreadily available hydrocarbon fuels, such as natural gas, nearatmospheric pressure operation, dose-coupled heating and coolingsystems, optimized power electronics, drop-in replacement for existingheating, cooling, and hot water systems, and grid integration.

FIG. 1 shows an exemplary CCHP system 100 according to an embodiment ofthe present invention. At a high level, CCHP system 100 includes a fuelcell system 104, a waste heat recovery system 108, and a control system112. In operation, and as explained in more detail below, fuel cellsystem 104 uses a refined mixture of water, air, and hydrogen to produceelectrical energy and thermal energy. As with most fuel cells, fuel cellsystem 104 must be kept within a predetermined temperature range inorder to promote efficient operation of the cell. Thus, at least aportion of the thermal energy produced by fuel cell system 104 isremoved by waste heat recovery system 108, which, as described morefully below, is designed and configured to make the fuel cell system'sthermal energy available for both reuse within the fuel cell system aswell as heating and cooling of the structure, e.g., residence,commercial building, etc., where CCHP system 100 resides.

FIG. 2 shows the primary components of an exemplary fuel cell system104. As shown, fuel cell system 104 includes a fuel-air water delivery(FAWD) module 116, a reactant processing module 120, a power generationmodule 124, and a power conditioning module 128.

At a high level, FAWD module 116 receives fuel, air, water, and heat asinputs, and produces a desulfurized, humidified fuel stream, i.e., arefined fuel stream 132, as an output. The fuel used in fuel cell system104 generally varies by the type of fuel cell employed. For example,hydrogen, methanol, dilute light hydrocarbons like methane (by itself orin the form of natural gas) and propane are used by common fuel celltypes. As discussed in more detail below, the type of fuel cell usedeffectively in fuel cell system 104 produces both electrical and thermalenergy in sufficient amounts for use in the structure in which it isdeployed. In an exemplary embodiment, a high temperature polymerelectrolyte membrane (PEM) fuel cell is used in fuel cell system 104 andthe input into FAWD module 116 is natural gas, which is generallyreadily commercially available, although other fuels could be used.

In an embodiment, FAWD module 116 can desulfurize the fuel (ifnecessary) by contacting the fuel with an adsorbent which preferentiallyadsorbs hydrogen sulfide, carbonyl sulfide, sulfide odorants, orcombinations thereof at a selected temperature and pressure. In analternative embodiment, FAWD module 116 can also include a hydrocarbondesulfurization bed, such as the hydrocarbon desulfurization beddescribed in Applicants' application entitled “System and Method ofRegenerating Desulfurization Beds in a Fuel Cell System,” U.S.Provisional Application Ser. No. 61/788,300, filed on Mar. 15, 2013,which is incorporated by reference for its discussion of the same.

FAWD module 116 may also further condition the fuel by altering thewater content of the fuel to an appropriate level for the fuel cellsystem 104. The humidity of the refined fuel stream 132 may be increasedby increasing the water input to the FAWD.

The input rate, temperature, pressure, and output of FAWD module 116 areregulated via control system 112, described in more detail below, so asto be responsive to the needs of the structure (e.g., thermal andelectrical loads) and to optimize the utilization and efficiency of theCCHP system 100.

FAWD module 116 supplies refined fuel stream 132 to reactant processingmodule 120. Reactant processing module 120 provides the conditionsnecessary to deliver a reformate stream 136 to power generation module124 that contains primarily H₂, CO, CO₂, CH₄, N₂, and H₂O. The tworeactions, which generally take place within reactant processing module120 and convert the refined fuel stream into hydrogen, are shown inequations (1) and (2).

½O₂+CH₄→2H₂CO  Equation (1):

H₂0+CH₄→3H₂CO  Equation (2):

The reaction shown in equation (1) is sometimes referred to as catalyticpartial oxidation (CPO). The reaction shown in equation (2) is generallyreferred to as steam reforming. Both reactions may be conducted at atemperature of about 100□ in the presence of a catalyst such asplatinum. Reactant processing module 120 may use either of thesereactions separately or in combination. While the CPO reaction isexothermic, the steam reforming reaction is endothermic. Reactorsutilizing both reactions to maintain a relative heat balance aresometimes referred to as autothermal (ATR) reactors.

As evident from equations (1) and (2), both reactions produce carbonmonoxide (CO). Such CO is generally present in amounts greater than10,000 parts per million (ppm). In certain embodiments, because of thehigh temperature at which the power generation module 124 is operated,this CO acts as a fuel dilutant instead of a catalyst poison andgenerally does not affect the operation or long term health of thesystem.

Notably, the use of a high temperature PEM fuel cell (as opposed to alow temperature PEM fuel cell system (e.g., less than 100° C. operatingtemperature) substantially avoids the problem of removing most of the COfrom the reformate stream 136. Should additional CO removal be desired,however, reactant processing module 120 may employ additional reactionsand processes to reduce the CO that is produced. For example, twoadditional reactions that may be used are shown in equations (3) and(4). The reaction shown in equation (3) is generally referred to as theshift reaction, and the reaction shown in equation (4) is generallyreferred to as preferential oxidation (PROX).

CO+H₂O→H₂+CO₂  Equation (3):

CO+½O₂→CO₂  Equation (4):

Various catalysts and operating conditions are known for accomplishingthe shift reaction. For example, the reaction may be conducted at atemperature from about 300-600° C. in the presence of supportedplatinum. Other catalysts and operating conditions are also known. Suchsystems operating in this temperature range are typically referred to ashigh temperature shift (HTS) systems. The shift reaction may also beconducted at lower temperatures, such as 100-300° C., in the presence ofother catalysts such as, but not limited to, copper supported ontransition metal oxides. Such systems operating in this temperaturerange are typically referred to as low temperature shift (LTS) systems.

The PROX reaction may also be used to further reduce CO. The PROXreaction is generally conducted at lower temperatures than the shiftreaction, such as between about 100-200° C. Like the CPO reaction, thePROX reaction can also be conducted in the presence of an oxidationcatalyst such as platinum. The PROX reaction can typically achieve COlevels less than about 100 ppm (e.g., less than 50 ppm). Reactantprocessing module 124 can include additional or alternatives steps thanthose listed above to remove CO as is known in the art, and it is knownthat other processes to remove CO may be used.

In addition to converting the refined fuel stream 132 for use withinpower generation module 124 and removing undesirable components,reactant processing module 120 also removes heat from refined fuelstream 132. In an exemplary embodiment, heat removal is provided by athermal fluid loop (not shown), which acts as a heat exchanger to removeheat from refined fuel stream 132 before the stream exits as reformatestream 136. Additional exemplary reactant processing modules aredescribed in U.S. Pat. Nos. 6,207,122, 6,190,623, and 6,132,689, whichare hereby incorporated by reference for their description of the same.In an exemplary embodiment, reactant processing module 120 includes ahybrid autothermal steam reformer of the type described in Applicants'application entitled “Hybrid Autothermal Steam Reformer for Fuel CellSystems,” U.S. Provisional Application Ser. No. 61/784,894, filed onMar. 14, 2013, which is incorporated by reference for its disclosure ofthe same.

Reformate stream 136 is provided as an input to power generation module124. Power generation module 124 is a device capable of producingelectric power and concomitantly generating thermal energy. In anexemplary embodiment, power generation module 124, when operating, iscapable of producing thermal energy at a temperature of between about120° C. and about 190° C. In another exemplary embodiment, powergeneration module 124, when operating, is capable of producing thermalenergy at about 1.5 kw of thermal energy per 1 kW of electrical energy.In another exemplary embodiment, power generation module 124 is a hightemperature polymer electrolyte membrane (PEM) fuel cell (sometimesreferred to as proton exchange membrane fuel cell), such as the PEM fuelcell 200 shown in FIG. 3.

In PEM fuel cell 200, a membrane 204, such as, but not limited to aphosphoric acid-doped cross-linked porous polybenzimidazole membrane,permits only protons 216 to pass between an anode 208 and a cathode 212.At anode 208, reformate stream 136 from reactant processing module 120is reacted to produce protons 216 that pass through membrane 204. Theelectrons 220 produced by this reaction travel through circuitry 224that is external to PEM fuel cell 200 to form an electrical current. Atcathode 212, oxygen is reduced and reacts with protons 216 to formwater. The anodic and cathodic reactions are described by the followingequations (1) and (2), respectively:

H₂→2H⁺2e ⁻  Equation (1):

O₂+4H⁺+4e ⁻→2H₂O  Equation (2):

A typical single fuel cell has a terminal voltage of up to approximatelyone volt DC. For purposes of producing much larger voltages, severalfuel cells may be assembled together to form an arrangement called afuel cell stack—an arrangement in which the fuel cells are electricallycoupled together in series to form a larger DC voltage (a voltage near100 volts DC, for example) and thus to provide more power and morethermal energy. An exemplary description of a fuel cell stack is foundin U.S. Pat. No. 6,534,210, titled “Auxiliary Convective Fuel CellStacks for Fuel Cell Power Generation Systems,” which is incorporated byreference for its discussion of the same. Typically, the fuel cell stackmay include flow plates (graphite, composite, or metal plates, asexamples) that are stacked one on top of the other. The flow plates mayinclude various surface flow channels and orifices to, as examples,route the reactants and products through the fuel cell stack. In theinstance of use of a fuel cell stack, several membranes 204 (each onebeing associated with a particular fuel cell) may be dispersedthroughout the fuel cell stack between anodes 208 and cathodes 212 ofdifferent fuel cells. Electrically conductive gas diffusion layers(GDLs) 232 may be located on each side of each membrane 204 to act as agas diffusion medium and in some cases to provide a support for fuelcell catalysts 228. In this manner, reactant gases from each side of themembrane 204 may pass along the flow channels and diffuse through theGDLs 232 to reach the membrane 204.

Returning to FIG. 2, power conditioning module 128 receives variable DCelectrical energy produced by power generation module 124 and outputsconditioned DC or AC power, depending on the desired application of theoutput power. In an embodiment, power conditioning module 128 convertsvariable, low-voltage DC power from the power generation module 124using a highly efficient, high boost ratio (e.g., >5:1), variable lowvoltage input, bi-directional DC-DC converter connected to a highlyefficient bi-directional inverter connected to the electrical grid. Anexample of a highly efficient, high boost ratio, bi-directional DC-DCconverter is found in Applicants' application entitled, “PowerConversion System with a DC to DC Boost Converter,” U.S. ProvisionalApplication Ser. No. 61/781,965, filed on Mar. 14, 2013, which isincorporated by reference for its discussion of the same. Powerconditioning module 128 may also be designed and configured to provideconditioned power to the structure, for example, for residential uses.In another embodiment, power conditioning module 128 conditions powerfor both local loads, e.g., battery-powered cars, battery strings, otherresidential or light commercial loads, and for the electric grid. Inthis embodiment, if local loads are not high enough to use all of thepower produced by the power generation module 124, the excess electricalpower is conditioned for input to the electric grid.

As discussed previously, CCHP system 100 includes a waste heat recoverysystem 108, an exemplary embodiment of which is shown in FIG. 4. Wasteheat recovery system 108 includes a thermal management module 144, aburner module 148, a cooling system 152, and a distribution system 156.

Thermal management module (TMM) 144 assists in controlling the operatingtemperatures of FAWD 108, reactant processing module 120, and powergeneration module 124, and directs thermal energy, as needed by thestructure, to cooling system 152, and a distribution system 156. TMM 144manages the heat distribution throughout CCHP system 100 primarily via aheat transfer loop 140. Heat transfer loop 140 includes valves and pumps(not shown) that are controlled by control system 112 so as to providethe proper rate of fluid flow in the heat transfer loop. Metrics thatare considered in determining the rate of fluid flow include, but arenot limited to, a pump speed, a fuel cell stack inlet temperature, afuel cell stack outlet temperature, a valve setting, and a returntemperature from heat transfer loop 140, so as to provide efficient heatgeneration and distribution.

In an exemplary embodiment, the rate of fluid flow is determined byreceiving a command for heating or cooling to a load in need thereof andproviding stored heat or cooling to the load. If stored capacity isunable to satisfy the load demand from storage, burner module 148(discussed further below) provides heat to heat transfer loop 140. Heattransfer loop 140 is used to heat the power generation module, reactantprocessing module 120, and heating and/or cooling system. In thisembodiment, control system 112 can receive signals indicative of, forexample, temperature inside the structure, the temperature outside thestructure, and can use algorithms based on these signals to determinewhether to start the fuel cell and export power. If the fuel cell needsto be operated, fuel flows to FAWD module 116 and reactant processingmodule 120. Once reformate stream 132 is of sufficient quality, it isdelivered to the fuel cell, which begins to generate power and send heatto heat transfer loop 140. Control system 112 monitors temperature inheat transfer loop 140 and if necessary for heating or cooling, turningburner module 148 down or off as appropriate. In an exemplaryembodiment, peak heating or cooling demands are by controlling burnermodule 148 rather than oversizing the rest of CCHP system 100.

Burner module 148 generates on-demand heat for use in the structure,provides auxiliary heat for subsystems during the startup of reactantprocessing module 120 and power generation module 124, providesauxiliary heat for special operations, provides peak heat forapplication heating and cooling loads, and assists in completing thecombustion of unburned hydrocarbons, volatile organic compounds, orcarbon monoxide in the exhaust stream coming from FAWD module 116 aswell as the reactant processing and power generation modules. Burnermodule 148 is monitored for burn temperatures to ensure substantiallycomplete combustion of exhaust gases.

Cooling system 152 is used to deliver conditioned air to the structure.In an exemplary embodiment, cooling system 152 includes a reactor 160and an evaporator 164. Reactor 160 contains an active substance, such assalt, and evaporator 164 contains a volatile, absorbable liquid, such aswater. At a high level, the operation of this exemplary cooling system152 is as follows: (1) heat from TMM 144 is delivered to reactor andhence absorbed water is expelled from the reactor to the condenser, (2)when cooling is desired, a vacuum is applied to the evaporator 164, thewater begins to rapidly be removed from the evaporator, and theremaining water gets colder, By coupling a coiled tube proximate to theevaporator, a liquid can be cooled and subsequently used for coolingwithin the structure.

Distribution system 156 manages the heat provided by TMM 144 to theapplication (e.g., residence, light industrial). In an exemplaryembodiment, distribution system 156 includes appropriate fan/pump andconnected ducting/piping to provide heat to the structure.

Control system 112 is designed and configured to manage the componentsof CCHP system 100 by collecting information from inputs that areinternal and external to the system. Those inputs that are internal tothe system include, but are not limited to, a reactant processingtemperature, a FAWD blower/pump speed, a TMM temperature, a TMM pumpspeed, a stack inlet temp, a stack outlet temp, a valve setting, a stackvoltage, a stack DC power output, an inverter power output, an air massflow rate, and a fuel mass flow rate. Those inputs that are external tothe system include, but are not limited to, a heat demand, a coolingdemand (e.g., thermostat information), a hot water demand, and a loaddemand. Information collected by control system 112 is input intoprogrammed algorithms, set points, or lookup tables so as to determineoperating parameters for CCHP system 100 components, control signals,and/or to generate external data for use in evaluating the efficiency,lifespan, or diagnosing problems with the CCHP system. Although controlsystem 112 is presently described as a separate component of CCHP system100, it is understood that control system 112 can be dispersed among thevarious components described herein without affecting the function ofthe CCHP system.

In general, for fuel cell system 104, power generation is increased byraising fuel and air flow to the fuel cell in proportion to thestoichiometric ratios dictated by the equations listed above. Thus,control system 112 may monitor, among other things, the output power ofpower generation module 124 and/or the thermal energy output, and basedon the monitored output power and voltage of the fuel cell, estimate thefuel and air flows required to satisfy the power demand by the thermalor electrical load of the structure. The ratio of fuel or air providedto a fuel cell over what is theoretically required by a given powerdemand is sometimes referred to as “stoich”. For example, 1 anode stoichrefers to 100% of the hydrogen theoretically required to meet a givenpower demand, whereas 1.2 stoich refers to 20% excess hydrogen over whatis theoretically required.

As briefly discussed above, CCHP system 100 may provide power to a load,such as a load that is formed from residential appliances and electricaldevices that may be selectively turned on and off to vary the power thatis demanded. Thus, in some applications the electric load required ofCCHP system 100 may not be constant, but rather the power that isconsumed by the load may vary over time and/or change abruptly.Moreover, thermal loads required by the structure, such as heatingrequirements in the fall and winter months or cooling requirements inthe summer, with or without electric load demands, may place differentdemands on the CCHP system 100. The availability of power and thermalcapacity from CCHP system 100 is controlled by control system 112.

Another embodiment of a CCHP system according to the present disclosureis shown in FIG. 5. In this embodiment, CCHP 300 includes the primarycomponents of CCHP 100 (not labeled for clarity) in a single structureor enclosure 304, which can be sized and configured to drop in as areplacement for a traditional heating, cooling, and water heating unit.Auxiliary components, such as auxiliary heating equipment 308, auxiliarypower equipment 312, and auxiliary cooling equipment 316, whileincluding items such as duct work for distributing heated air throughouta structure, are each also typically designed and configured such thatthe CCHP 300 is not “overdesigned.” For example, CCHP 300 may bedesigned to heat the structure in which it resides on all but the 3% ofcoldest days and to rely on the auxiliary heating equipment 308 toprovide the additional heat on those days. In this way, CCHP 300 is notoverdesigned by being sized to handle all possible heating loads.Similarly, CCHP 300 need not be designed to meet all possible cooling orpower loads, as auxiliary cooling equipment 316 and auxiliary powerequipment 312 can assist during peak demand times.

Among the advantages of one or more of the exemplary CCHP systems asdescribed herein are:

1. The CCHP system can allow for high utilization (approaching, and attimes including, 100%) of the fuel cell, allowing for substantial use ofthe electric and thermal power during varying electric and thermal loadconditions. In an exemplary embodiment, the CCHP system can allowutilization of the fuel cell approaching 100%.

2. Substantial energy recovery is achieved by storing thermal energyproduced by the fuel cell system.

3. The CCHP system is capable of using readily available hydrocarbonfuels such as natural gas and propane instead of expensive,difficult-to-obtain fuels such as hydrogen or methanol. Moreover, theuse of high-temperature PEM fuel cells as proposed herein lessens theneed for expensive steam or low efficiency, low temperature shiftreformers.

4. The CCHP system can operate near atmospheric pressure, therebyincreasing the system efficiency of the appliance by reducing parasiticlosses from compressors and blowers (sometimes used to increase powerdensity by pressurizing feed streams to manage liquid water in thesystem). For example, the CCHP system is about 20% more efficient thansimilar systems that use compressors. The CCHP system does not requireliquid water management, and power density is traded off for systemefficiency.

5. The CCHP system uses close-coupled heating and cooling systems, whichshare plumbing and heat transfer media, thereby creating a simple,integrated appliance.

6. The CCHP system can include optimized power electronics, such aspower conditioning system 120, which assists in maximizing powergeneration, extending fuel cell stack life, and providing high systemefficiency.

7. The CCHP system is designed and configured as a drop-in replacementfor existing heating, cooling, and hot water systems, thereby reducingthe expense of using the CCHP system as a replacement. Moreover, byusing the grid to supplement the CCHP system during peak load, the mostexpensive component in the system, the fuel cell system can beright-sized for maximum utilization, rather than sizing the fuel cellsystem for peak load power usage (ensuring an over-capacity componentthat is challenged to return its capital cost) or under-sizing the fuelcell system such that it runs beneath the power usage profile of theapplication.

Turning now to an exemplary operation of CCHP system 100 and withreference to exemplary embodiments shown in FIGS. 1-4 and in additionwith reference to FIG. 6, there is shown a process 400.

At step 404, there is a determination of the load of the structure oroutside load or both. In this embodiment, “load” may mean power needs,heating needs, or cooling needs, or any combination of the same. Theload may be determined by a control system, such as control system 112,which monitors activity in the structure such as, but not limited to,activation of machinery or appliances, changes in temperature within thestructure or external to the structure, or via preprogrammed routines orany combination of the aforementioned. Control system 112 may alsoreceive external information, such as that the power rebates from theprovision of power to the utility grid are beneficial to generate powerfor delivery to the grid.

At step 408, there is a determination as to which energy sources wouldbe necessary to meet the load demands of the structure/outside load. Incertain embodiments, there may be multiple simultaneous load demands ofdifferent types,

At step 412, energy is provided to meet the load demand. For example,power may be produced by a CCHP, such as CCHP system 100, in order tomeet electrical load demands of the structure.

At step 416, the co-produced energy, i.e., heat or cooling if electricalpower is needed or electrical power if heat or cooling is need, isdelivered and stored. For example, if the structure is demandingelectrical load, but no other load is required, the CCHP system maystore the heat generated by operating the fuel cell system in the coolersystem for later use. Alternatively, heat may be stored in a water tankor other heat sink for later use. If heat is needed, the electricalenergy produced by the fuel cell may be delivered to the electricalgrid.

FIG. 7 shows a diagrammatic representation of one implementation of amachine/computing device 500 that can be used to implement a set ofinstructions for causing one or more control systems of CCHP system 100,for example, device 500, to perform any one or more of the aspectsand/or methodologies of the present disclosure. Device 500 includes aprocessor 505 and a memory 510 that communicate with each other, andwith other components, such as control system 112, fuel cell system 104,or waste heat recovery system 108, via a bus 515. Bus 515 may includeany of several types of communication structures including, but notlimited to, a memory bus, a memory controller, a peripheral bus, a localbus, and any combinations thereof using any of a variety ofarchitectures.

Memory 510 may include various components (e.g., non-transitorymachine-readable media) including, but not limited to, a random accessmemory component (e.g., a static RAM “SRAM,” a dynamic RAM “DRAM,”etc.), a read-only component, and any combinations thereof. In oneexample, a basic input/output system 520 (BIOS), including basicroutines that help to transfer information between elements withindevice 500, such as during start-up, may be stored in memory 510. Memory510 may also include (e.g., stored on one or more non-transitorymachine-readable media) instructions (e.g., software) 525 embodying anyone or more of the aspects and/or methodologies of the presentdisclosure. In another example, memory 510 may further include anynumber of program modules including, but not limited to, an operatingsystem, one or more application programs, other program modules, programdata, and any combinations thereof.

Device 500 may also include a storage device 530. Examples of a storagedevice (e.g., storage device 530) include, but are not limited to, ahard disk drive for reading from and/or writing to a hard disk, amagnetic disk drive for reading from and/or writing to a removablemagnetic disk, an optical disk drive for reading from and/or writing toan optical media (e.g., a CD, a DVD, etc.), a solid-state memory device,and any combinations thereof. Storage device 530 may be connected to bus515 by an appropriate interface (not shown). Example interfaces include,but are not limited to, SCSI, advanced technology attachment (ATA),serial ATA, universal serial bus (USB), IEEE 1395 (FIREWIRE), and anycombinations thereof. In one example, storage device 530 may beremovably interfaced with device 500 (e.g., via an external portconnector (not shown)). Particularly, storage device 530 and anassociated machine-readable medium 535 may provide nonvolatile and/orvolatile storage of machine-readable instructions, data structures,program modules, and/or other data for device 500. In one example,instructions 525 may reside, completely or partially, withinmachine-readable medium 535. In another example, instructions 525 mayreside, completely or partially, within processor 505.

Device 500 may also include a connection to one or more systems ormodules included with CCHP system 100. Any system or device may beinterfaced to bus 515 via any of a variety of interfaces (not shown)including, but not limited to, a serial interface, a parallel interface,a game port, a USB interface, a FIREWIRE interface, a direct connectionto bus 515, and any combinations thereof. Alternatively, in one example,a user of device 500 may enter commands and/or other information intodevice 500 via an input device (not shown). Examples of an input deviceinclude, but are not limited to, an alpha numeric input device (e.g., akeyboard), a pointing device, a joystick, a gamepad, an audio inputdevice (e.g., a microphone, a voice response system, etc.), a cursorcontrol device (e.g., a mouse), a touchpad, an optical scanner, a videocapture device (e.g., a still camera, a video camera), touchscreen, andany combinations thereof.

A user may also input commands and/or other information to device 500via storage device 530 (e.g., a removable disk drive, a flash drive,etc.) and/or a network interface device 545. A network interface device,such as network interface device 545, may be utilized for connectingdevice 500 to one or more of a variety of networks, such as network 550,and one or more remote devices 555 connected thereto. Examples of anetwork interface device include but are not limited to, a networkinterface card, a modem, and any combination thereof. Examples of anetwork include, but are not limited to, a wide area network (e.g., theInternet, an enterprise network), a local area network (e.g., a networkassociated with an office, a building, a campus, or other relativelysmall geographic space), a telephone network, a direct connectionbetween two computing devices, and any combinations thereof. A network,such as network 550, may employ a wired and/or a wireless mode ofcommunication. In general, any network topology may be used. Information(e.g., data, instructions 525, etc.) may be communicated to and/or fromdevice 500 via network interface device 555.

Device 500 may further include a video display adapter 560 forcommunicating a displayable image to a display device 565. Examples of adisplay device 565 include, but are not limited to, a liquid crystaldisplay (LCD), a cathode ray tube (CRT), a plasma display, and anycombinations thereof.

In addition to display device 565, device 500 may include a connectionto one or more other peripheral output devices including, but notlimited to, an audio speaker, a printer, and any combinations thereof.Peripheral output devices may be connected to bus 515 via a peripheralinterface 570. Examples of a peripheral interface include, but are notlimited to, a serial port, a USB connection, a FIREWIRE connection, aparallel connection, a wireless connection, and any combinationsthereof.

A digitizer (not shown) and an accompanying pen/stylus, if needed, maybe included in order to digitally capture freehand input. A pendigitizer may be separately configured or coextensive with a displayarea of display device 565. Accordingly, a digitizer may be integratedwith display device 565, or may exist as a separate device overlaying orotherwise appended to display device 565.

According to an embodiment of the present disclosure, there is describeda combined cooling, heating, and power (CCHP) system for a structurecomprising an electric power generator that simultaneously produceselectrical and thermal energy; a waste heat recovery system designed andconfigured to cool ambient air and to receive the thermal energy fromthe electric power generator, the waste heat recovery system having atleast two modes of operation; wherein in a first mode of operation thewaste heat recovery system stores the thermal energy from the electricpower generator, and wherein in a second mode of operation the wasteheat recovery system uses the stored thermal energy to cool ambient air;and a control system designed and configured to control the electricpower generator and the waste heat recovery system such that theelectric power generator supplies electricity to the structure and/orthermal energy to the waste heat recovery system. Further, wherein theelectric power generator is a fuel cell. Further, wherein the electricpower generator is a fuel cell having an operating temperature betweenabout 120° C. and 190° C. Further, wherein the electric power generatoris a high temperature PEM fuel cell. Also, wherein the electric powergenerator is connected to a load and an electrical grid. Further,wherein the control system diverts electric power to the electrical gridif the electric power generator produces more electrical energy than isrequired by the load.

According to another embodiment of the present disclosure, there isdescribed a combined cooling, heating, and power (CCHP) system for astructure having thermal, and electrical loads, the CCHP systemcomprising: a housing; an electric power generator disposed within thehousing; a power conversion module electrically coupled to the electricpower generator and the structure, the power conversion module beingdisposed within the housing; a waste heat recovery system thermallycoupled to the electric power generator and the structure, the wasteheat recovery system having a thermal management system disposed withinthe housing and a cooling system disposed proximate the housing; and acontrol system electrically coupled to the electric power generator,power conversion module, and waste heat recovery system, wherein thecontrol system is designed and configured to determine, based upon aninstantaneous thermal load and electrical load of the structure,operational characteristics of the electric power generator.

Exemplary embodiments have been disclosed above and illustrated in theaccompanying drawings. It will be understood by those skilled in the artthat various changes, omissions, and additions may be made to that whichis specifically disclosed herein without departing from the spirit andscope of the present invention.

What is claimed is:
 1. A combined cooling, heating, and power (CCHP)system for delivering thermal energy and electrical energy to astructure in need thereof, the CCHP system comprising: an energygenerator that simultaneously produces electrical energy and thermalenergy as an output; a waste heat recovery system thermally coupled tothe energy generator and including: a distribution system for deliveringthermal energy to the structure; and a cooling system for providingconditioned air to the structure; wherein the waste heat recovery systemis configured to: recover thermal energy from the energy generator;return a first portion of the recovered thermal energy to the energygenerator; and deliver a second portion of the recovered energy to thedistribution system or the cooling system depending on present or futureneeds of the structure; a DC to DC boost converter (DDBC) electronicallycoupled to the energy generator and configured to condition theelectrical energy for use by the structure, the DDBC including aplurality of interleaved, isolated, full-bridge DC-DC convertersarranged in a Delta-Wye configuration and a multi-leg bridge; and acontrol system configured to manage the energy generator and the wasteheat recovery system by: collecting at least one internal input;collecting at least one external input; determining operating parametersfor the CCHP system based on the internal input and the external input;and generating data for use in evaluating the efficiency of the CCHPsystem based on the internal input and the external input.
 2. The CCHPsystem according to claim 1, wherein the energy generator is a fuelcell.
 3. The CCHP system according to claim 2, wherein the controlsystem monitors a load demand of the structure, monitors an output powerof the fuel cell, and estimates fuel and air flows required to generatethe output power to satisfy the load demand.
 4. The CCHP systemaccording to claim 1, wherein the energy generator is a polymerelectrolyte membrane fuel cell.
 5. The CCHP system according to claim 3,wherein the control system collects multiple internal inputs thatinclude a reactant processing temperature, a FAWD blower/pump speed, aTMM temperature, a TMM pump speed, a stack inlet temp, a stack outlettemp, a valve setting, a stack voltage, a stack DC power output, aninverter power output, an air mass flow rate, and a fuel mass flow rate.6. The CCHP system according to claim 5, wherein the control systemcollects multiple external inputs that include a heat demand, a coolingdemand, a hot water demand, and the load demand.
 7. The CCHP systemaccording to claim 2, wherein the control system is configured tocontrol the fuel cell and the waste heat recovery system such that thestructure utilizes about 100% of the electrical and thermal energyproduced by the fuel cell.
 8. The CCHP system according to claim 1,wherein the energy generator uses natural gas or propane as a fuel. 9.The CCHP system according to claim 1, wherein the system furtherincludes an auxiliary burner, wherein the auxiliary burner is used tomeet a thermal load of the structure when there is no electrical loadneeded by the structure.
 10. The CCHP system according to claim 1,wherein the CCHP system is sized and configured as a drop-in replacementfor an existing residential or light commercial heating, cooling, andhot water system.
 11. A combined cooling, heating, and power (CCHP)system for use in a residential or light commercial structure havingelectric and thermal loads, the CCHP system comprising: a fuel cellsystem having a thermal output and an electrical output; a waste heatrecovery system including: a thermal management module; a storagesystem; a distribution system; and a cooling system; a DC to DC boostconverter (DDBC) electronically coupled to the electrical output andconfigured to condition the electrical output for use by the structure,the DDBC including a plurality of interleaved, isolated, full-bridgeDC-DC converters arranged in a Delta-Wye configuration and a multi-legbridge; and a control system in communication with the fuel cell systemand the waste heat recovery system, the control system configured to:receive a signal representative of a required electrical load and arequired thermal load; determine whether any additional loads arerequired by the structure after receiving the signal; collect at leastone internal input from the fuel cell system; collect at least oneexternal input that is external from the fuel cell system; and determineoperating parameters for the fuel cell system and the waste heatrecovery system based on the internal input and the external input so asto maximize the utilization of the electrical output and the thermaloutput of the fuel cell system.
 12. The CCHP system according to claim11, wherein the control system generates data for use in evaluating theefficiency of the CCHP system based on the internal input and theexternal input.
 13. The CCHP system according to claim 11, wherein thecontrol system collects multiple internal inputs that include a reactantprocessing temperature, a FAWD blower/pump speed, a TMM temperature, aTMM pump speed, a stack inlet temp, a stack outlet temp, a valvesetting, a stack voltage, a stack DC power output, an inverter poweroutput, an air mass flow rate, and a fuel mass flow rate.
 14. The CCHPsystem according to claim 13, wherein the control system collectsmultiple external inputs that include a heat demand, a cooling demand,and a hot water demand.
 15. The CCHP system according to claim 11,wherein the waste heat recovery system is configured to recover thermalenergy from the fuel cell system and to return a first portion of therecovered thermal energy to the fuel cell system and a second portion ofthe recovered energy to the distribution system, the storage system, orthe cooling system.
 16. The CCHP system according to claim 11, whereinthe fuel cell system includes a polymer electrolyte membrane fuel cell.17. The CCHP system according to claim 11, wherein the control system isconfigured to control the outputs of the fuel cell system and the wasteheat recovery system so as to utilize about 100% of the electrical andthermal energy produced by the fuel cell system after receiving thesignal.
 18. The CCHP system according to claim 11, wherein the fuel cellsystem uses natural gas as a fuel.
 19. The CCHP system according toclaim 11, wherein the fuel cell system is electronically coupled to anexternal power grid and wherein the control system determines whetherthe fuel cell produces electric power for the external power grid. 20.The CCHP according to claim 11, wherein a first portion of the CCHPsystem resides within one of a plurality of enclosures, the firstportion including the fuel cell system and the thermal managementmodule.